Semiconductor device including a Fin-FET and method of manufacturing the same

ABSTRACT

A method of forming a semiconductor device including a fin field effect transistor (FinFET), the method includes forming a first sacrificial layer over a source/drain structure of a FinFET structure and an isolation insulating layer. The first sacrificial layer is patterned, thereby forming an opening. A first liner layer is formed on the isolation insulating layer in a bottom of the opening and on at least side faces of the patterned first sacrificial layer. After the first liner layer is formed, forming a dielectric layer in the opening. After the dielectric layer is formed, removing the patterned first sacrificial layer, thereby forming a contact opening over the source/drain structure. A conductive layer is formed in the contact opening. The FinFET is an n-type FET, and the source/drain structure includes an epitaxial layer made of Si1-y-a-bGeaSnbM2y, wherein 0&lt;a, 0&lt;b, 0.01≤(a+b)≤0.1, 0.01≤y≤0.1, and M2 is P or As.

CROSS REFERENCE TO RELATED APPLICATION

The Application is a Divisional Application of U.S. application Ser. No.15/665,230 filed Jul. 31, 2017, now U.S. Pat. No. 10,685,884, thesubject matter of which is incorporated herein by reference in entirety.

TECHNICAL FIELD

The disclosure relates to method of manufacturing semiconductorintegrated circuits, and more particularly to method of manufacturingsemiconductor devices including fin field effect transistors (FinFETs),and semiconductor devices.

BACKGROUND

As the semiconductor industry has progressed into nanometer technologyprocess nodes in pursuit of higher device density, higher performance,and lower costs, challenges from both fabrication and design issues haveresulted in the development of three-dimensional designs, such as a finfield effect transistor (Fin FET) and the use of a metal gate structurewith a high-k (dielectric constant) material. The metal gate structureis often manufactured by using gate replacement technologies, andsources and drains are formed by using an epitaxial growth method.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 illustrates experimental results of various epitaxial layers fora source/drain region of an n-type field effect transistor in accordancewith embodiments of the present disclosure.

FIGS. 2A and 2B illustrate experimental results showing Ge concentrationeffects on electrical properties.

FIGS. 3A, 3B and 3C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 4A, 4B and 4C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 5A, 5B and 5C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 6A, 6B and 6C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 7A, 7B and 7C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 8A, 8B and 8C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 9A, 9B and 9C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 10A, 10B and 10C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 11A, 11B and 11C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 12A, 12B and 12C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 13A, 13B and 13C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 14A, 14B and 14C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 15A, 15B and 15C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 16A, 16B and 16C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 17A, 17B and 17C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 18A, 18B, 18C and 18D illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 19A, 19B and 19C illustrate one of the various stages in asemiconductor device fabrication process in accordance with embodimentsof the present disclosure.

FIGS. 20A, 20B and 20C illustrate one of the various stages in asemiconductor device fabrication process in accordance with otherembodiments of the present disclosure.

FIGS. 21A, 21B and 21C illustrate one of the various stages in asemiconductor device fabrication process in accordance with otherembodiments of the present disclosure.

FIGS. 22A, 22B and 22C illustrate one of the various stages in asemiconductor device fabrication process in accordance with otherembodiments of the present disclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof the invention. Specific embodiments or examples of components andarrangements are described below to simplify the present disclosure.These are, of course, merely examples and are not intended to belimiting. For example, dimensions of elements are not limited to thedisclosed range or values, but may depend upon process conditions and/ordesired properties of the device. Moreover, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed interposing the first and second features, suchthat the first and second features may not be in direct contact. Variousfeatures may be arbitrarily drawn in different scales for simplicity andclarity. In the accompanied drawings, some layers/features may beomitted for simplification.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The device may be otherwise oriented (rotated 90 degrees orat other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly. In addition, the term“made of” may mean either “comprising” or “consisting of.” Further, inthe following fabrication process, there may be one or more additionaloperations in/between the described operations, and the order ofoperations may be changed.

Disclosed embodiments relate to methods and structures of formingsource/drain (S/D) structures for fin field-effect transistors(FinFETs), in particular for n-type FinFETS. The embodiments such asthose disclosed herein are generally applicable not only to FinFETs butalso to a planar type FET, a double-gate, surround-gate, omega-gate orgate-all-around transistor, a 2-dimentional FET and/or a nanowiretransistor, or any suitable device having source/drain epitaxialregions.

In order to achieve high-operational speed devices, carrier mobility ina channel region of an FET can be increased by applying appropriatestress to a crystalline semiconductor material in the channel region. Asone technique to apply the stress, a crystalline semiconductor materialhaving a different lattice constant than the channel region is providedat a source/drain region of the FET. A crystalline semiconductormaterial having a smaller lattice constant than the channel region isused in the source/drain (S/D) region of an n-type FET to apply tensilestress to the channel region. For example, SiP, SiC and/or SiCP are usedfor the S/D region of an n-type FET, where the channel region is made ofsilicon. On the other hand, a crystalline semiconductor material havinga larger lattice constant than the channel region is used in the S/Dregion of a p-type FET to apply compressive stress to the channelregion. For example, SiGe and/or Ge are used for the source/drain (S/D)region of a p-type FET, where the channel region is made of silicon. Thecrystalline semiconductor material for the S/D region is formed by anepitaxial growth method. In this disclosure, the term “source/drain” or“S/D” refers to a source and/or a drain and the source and the drainhave substantially the same structure with each other.

In the present disclosure, the inventors found that adding Ge in a SiPS/D epitaxial region can increase material thermal stability and improveelectrical properties of the S/D regions for an n-type FET.

For example, after the S/D epitaxial layers are formed, subsequentmanufacturing operations including various thermal operations areperformed to manufacture a semiconductor device. Such thermaloperations, however, decrease the number of active carriers in the S/Dregions, thereby increasing contact resistance between the S/D regionand an S/D contact metal. However, as shown below, the incorporation ofGe in the SiP epitaxial layer can release the local lattice stress morethan an SiP epitaxial layer without Ge, and can have more stable Pbinding energy than in the SiP epitaxial layer without Ge. Accordingly,it is possible to increase the thermal stability of the S/D epitaxiallayer. In addition, the SiP epitaxial layer including Ge (herein aftermay be referred to as “SiGeP”) can have a higher P (phosphorous)activation rate (greater number of activated P atoms) than the SiPepitaxial layer without Ge after the thermal operations.

FIG. 1 illustrates experimental results of various epitaxial layers fora source/drain region of an n-type field effect transistor in accordancewith embodiments of the present disclosure. In FIG. 1, the samplesincluding SiP and SiGeP epitaxial layers were prepared and the activephosphorous concentration and mobility of electrons were measured aftervarious thermal operations. In Conditions #3 and #4, Ge was introducedduring an epitaxial growth of SiP and in Condition #5, Ge was introducedby ion implantation after the SiP epitaxial growth.

As shown in FIG. 1, when Ge is included in the SiP epitaxial layer, thenumber of the active phosphorous becomes about 10 (ten) times or greaterthan the condition without Ge (compare Conditions #1 and #2 withConditions #3 and #4). Further, FIG. 1 shows that even though Ge, whichis a larger element in size than Si and would reduce the stress causedby SiP, is included, the mobility does not substantially change.Generally, when the phosphorous concentration increases, the mobilitydecreases. However, by including Ge into SiP, higher active phosphorousconcentrations were obtained at higher P concentration in SiP withoutsacrificing the mobility. It is noted that when Ge is introduced by ionimplantation, a similar increase in the number of active phosphorous wasnot obtained.

FIGS. 2A and 2B illustrate experimental results showing Ge concentrationeffects on electrical properties. In FIGS. 2A and 2B, the concentrationof P is 2.0×10²¹ cm⁻³ and thickness of the SiP (or SiGeP) epitaxiallayer is 50 nm, and the thermal operations same as those in Conditions#1 and #3 are performed. Ge is introduced during the epitaxial growth ofthe SiP layer. Two different pre-amorphization implantation (PAIs) areperformed. In FIGS. 2A and 2B, the concentration of Ge in SiGeP changesfrom 0.5×10²¹ cm⁻³ to 4.0×10²¹ cm⁻³ (0.5×10²¹ cm⁻³, 1.0×10²¹ cm⁻³ to,2.0×10²¹ cm⁻³ and 4.0×10²¹ cm⁻³). When SiGeP is expressed bySi_(1-x-y)Ge_(x)P_(y), and the concentration Ge corresponds to about0.01≤x≤about 0.1. In some embodiments, the Ge amount is smaller than theP amount. In other embodiments, the Ge amount is larger than the Pamount.

As shown in FIG. 2A, when Ge is not included, the resistivity of the SiPepitaxial layer is about 0.45 mΩ·cm, and when Ge is included in SiP(e.g., about 0.01≤x≤about 0.1), the resistivity of SiGeP epitaxial layeris reduced to about 0.35 mΩ·cm. Further, in FIG. 2B, when Ge is notincluded, the de-activation rate of P in the SiP epitaxial layer isabout 25%, and when Ge is included in SiP (e.g., about 0.01≤x≤about0.1), the de-activation rate of P in the SiGeP epitaxial layer isreduced to about 10-15%. Instead of or in addition to Ge, Sn can beincluded in SiP. Instead of or in addition to P, As can be included.

FIGS. 3A-19C illustrate various processes in a semiconductor devicefabrication process in accordance with some embodiments of the presentdisclosure. Throughout the various views and illustrative embodiments,like reference numbers are used to designate like elements. In FIGS.3A-19C, the “A” figures (e.g., FIGS. 3A, 4A, etc.) illustrate aperspective view, the “B” figures (e.g., FIGS. 3B, 4B, etc.) illustratea cross-sectional view along the Y direction corresponding to line Y1-Y1illustrated in FIG. 3A, and the “C” figures (e.g., FIG. 3C, 4C, etc.)illustrate a cross-sectional view along the X direction corresponding toline X1-X1 illustrated in in FIG. 3A. It is understood that additionaloperations can be provided before, during, and after the processes shownby FIGS. 3A-19C, and some of the operations described below can bereplaced or eliminated, for additional embodiments of the method. Theorder of the operations/processes may be interchangeable. The entirecontents of U.S. patent application Ser. No. 15/620,063 are incorporatedherein by reference.

Referring first to FIGS. 3A-3C, FIGS. 3A-3C illustrate the structureafter dummy gate structures are formed. In FIGS. 3A-3C, there is shown asubstrate 101 having one or more fin structures, with two fin structures102 being illustrated. It is understood that two fin structures areillustrated for purposes of illustration, but other embodiments mayinclude any number of fin structures. In some embodiments, one or moredummy fin structures are formed adjacent to the fin structure for anactive FinFET. The fin structure 102 extends in the X direction andprotrudes from the substrate in the Z direction, while the gate 130extends in the Y direction.

The substrate 101 may comprise various doped regions depending on designrequirements (e.g., p-type substrate or n-type substrate). In someembodiments, the doped regions may be doped with p-type or n-typedopants. For example, the doped regions may be doped with p-typedopants, such as boron or BF₂; n-type dopants, such as phosphorus orarsenic; and/or combinations thereof. The doped regions may beconfigured for an n-type FinFET, or alternatively configured for ap-type FinFET.

In some embodiments, the substrate 101 may be made of a suitableelemental semiconductor, such as silicon, diamond or germanium; asuitable alloy or compound semiconductor, such as Group-IV compoundsemiconductors (silicon germanium (SiGe), silicon carbide (SiC), silicongermanium carbide (SiGeC), GeSn, SiSn, SiGeSn), Group III-V compoundsemiconductors (e.g., gallium arsenide, indium gallium arsenide InGaAs,indium arsenide, indium phosphide, indium antimonide, gallium arsenicphosphide, or gallium indium phosphide), or the like. Further, thesubstrate 101 may include an epitaxial layer (epi-layer), which may bestrained for performance enhancement, and/or may include asilicon-on-insulator (SOI) structure.

The fin structure 102 may be formed using, for example, a patterningprocess to form trenches such that a trench is formed between adjacentfin structures 102. As discussed in greater detail below, the finstructure 102 will be used to form a FinFET.

Isolation regions, such as shallow trench isolations (STI) 105, aredisposed in the trenches over the substrate 101. Prior to forming theisolation insulating layer 105, one or more liner layers are formed overthe substrate 101 and sidewalls of the bottom part 103 of the finstructures 102 in some embodiments. In some embodiments, the linerlayers includes a first fin liner layer 106 formed on the substrate 101and sidewalls of the bottom part 103 of the fin structures 102, and asecond fin liner layer 108 formed on the first fin liner layer 106. Eachof the liner layers has a thickness between about 1 nm and about 20 nmin some embodiments.

In some embodiments, the first fin liner layer 106 includes siliconoxide and has a thickness between about 0.5 nm and about 5 nm, and thesecond fin liner layer 108 includes silicon nitride and has a thicknessbetween about 0.5 nm and about 5 nm. The liner layers may be depositedthrough one or more processes such as physical vapor deposition (PVD),chemical vapor deposition (CVD), or atomic layer deposition (ALD),although any acceptable process may be utilized.

The isolation insulating layer 105 may be made of suitable dielectricmaterials such as silicon oxide, silicon nitride, silicon oxynitride,fluorine-doped silicate glass (FSG), low-k dielectrics such as carbondoped oxides, extremely low-k dielectrics such as porous carbon dopedsilicon dioxide, a polymer such as polyimide, combinations of these, orthe like. In some embodiments, the isolation insulating layer 105 isformed through a process such as CVD, flowable CVD (FCVD), or aspin-on-glass process, although any acceptable process may be utilized.Subsequently, portions of the isolation insulating layer 105 extendingover the top surfaces of the fin structures 102, and portions of theliner layers over the top surfaces of the fin structures 102 are removedusing, for example, an etch process, chemical mechanical polishing(CMP), or the like.

In some embodiments, the isolation insulating layer 105 and the linerlayers are recessed to expose the upper portion 104 of the fin structure102 as illustrated in FIGS. 3A-3C. In some embodiments, the isolationinsulating layer 105 and the liner layers are recessed using a singleetch processes, or multiple etch processes. In some embodiments in whichthe isolation insulating layer 105 is made of silicon oxide, the etchprocess may be, for example, a dry etch, a chemical etch, or a wetcleaning process. For example, the chemical etch may employfluorine-containing chemical such as dilute hydrofluoric (dHF) acid.After the fin formation process, the fin height H_(fin) is about 30 nmor higher, such as about 50 nm or higher, in some embodiments. In oneembodiment, the fin height is between about 40 nm and about 80 nm. It isunderstood that the fin height may be modified by subsequent processing.Other materials, processes, and dimensions may be used.

After the fin structure 102 is formed, a dummy gate structure includinga dummy gate dielectric layer 91 and a dummy gate electrode 90 areformed over the exposed fin structure 102. The dummy gate dielectriclayer 91 and the dummy gate electrode 90 will be subsequently used todefine and form the source/drain regions. In some embodiments, the dummygate dielectric layer 91 and the dummy gate electrode 90 are formed bydepositing and patterning a dummy dielectric layer formed over theexposed fin structures 102 and a dummy electrode layer over the dummygate dielectric layer. The dummy dielectric layer may be formed bythermal oxidation, CVD, sputtering, or any other methods known and usedin the art for forming a dummy dielectric layer. In some embodiments,the dummy dielectric layer 91 may be made of one or more suitabledielectric materials such as silicon oxide, silicon nitride, SiCN, SiON,and SiN, low-k dielectrics such as carbon doped oxides, extremely low-kdielectrics such as porous carbon doped silicon dioxide, a polymer suchas polyimide, the like, or a combination thereof. In one embodiment,SiO₂ is used.

In some embodiments, the dummy electrode layer 90 is a conductivematerial and may be selected from a group comprising amorphous silicon,poly silicon, amorphous germanium, poly germanium, amorphoussilicon-germanium, poly silicon-germanium, metallic nitrides, metallicsilicides, metallic oxides, and metals. The dummy electrode layer may bedeposited by PVD, CVD, sputter deposition, or other techniques known andused in the art for depositing conductive materials. Other materials,conductive and non-conductive, may be used. In one embodiment, poly-Siis used.

A mask pattern may be formed over the dummy electrode layer to aid inthe patterning. In some embodiments, a hard mask pattern including afirst layer 80 and a second layer 82 is formed over a blanket layer ofpolysilicon. The hard mask pattern is made of one or more layers ofSiO₂, SiCN, SiON, Al₂O₃, SiN, or other suitable materials. In certainembodiments, the first layer 80 includes silicon nitride (SiN) and thesecond layer 82 includes silicon oxide. By using the mask pattern as anetching mask, the dummy electrode layer is patterned into the dummy gateelectrode 90. In some embodiments, the dummy dielectric layer 91 is alsopatterned to define the dummy gate dielectric layer.

Subsequently, sidewall spacers 134 are formed along sidewalls of thedummy gate structure. The sidewall spacers 134 may be formed bydepositing and anisotropically etching an insulating layer depositedover the dummy gate structures, the fin structure 102, and the isolationinsulating layer 105. In some embodiments, the sidewall spacers 134 areformed of silicon nitride, and have a single-layer structure. Inalternative embodiments, the sidewall spacers 134 may have a compositestructure including a plurality of layers. For example, the sidewallspacers 134 include a silicon oxide layer and a silicon nitride layerover the silicon oxide layer. Other materials, such as SiO₂, SiCN, SiON,SiN, SiOCN, other low k material, or combinations thereof, may also beused. The thickness of the sidewall spacer 134 is in a range from about5 nm to about 40 nm in some embodiments.

After the dummy gate structure and the sidewall spacers are formed,source/drain (S/D) structures 120 and 121 are formed on exposed portions104 of the fin structures 102 along opposing sides of the dummy gatestructure, as shown in FIGS. 4A-4C. The S/D structures 120 and 121 maybe epitaxially formed on the side faces and the top face of the exposedfin structure 104. In some embodiments, the fin structure 104 may berecessed and the S/D structure is epitaxially formed on the exposedportion of the recessed fin. The use of epitaxial grown materials in thesource/drain regions allows for the source/drain regions to exert stressin a channel of a FinFET. When the S/D structures 120 and 121 are fordifferent conductivity type FETs, the S/D structure 120 is formed whilethe fin structure for the S/D structure 121 is covered by a protectivelayer made of, for example, SiN, and then the S/D structure 121 isformed while the formed S/D structure 120 is covered by a protectivelayer. In one embodiment, the S/D structure 120 is for an n-type FinFETand the S/D structure 121 is for a p-type FinFET.

The materials used for the S/D structures 120 and 121 may be varied forn-type and p-type FinFETs, such that one type of material is used forthe n-type FinFETs to exert a tensile stress in the channel region andanother type of material for the p-type FinFETs to exert a compressivestress.

For the n-type FinFET, the S/D structure 120 includes an epitaxial layerincluding Si_(1-x-y)M1_(x)M2_(y), where M1 is one or more of Ge and Sn,and M2 is one or more of P and As, and about 0.01≤x≤about 0.1 (about 1to about 10 mol %) and about 0.01≤y≤about 0.1. In certain embodiments, xis smaller than y. In other embodiments, x is larger than y. In someembodiments, as set forth above, Si_(1-x-y)Ge_(x)P_(y), where about0.01≤x≤about 0.1 (about 1 to about 10 mol %) and about 0.01≤y≤about 0.1,is formed as the S/D structure 120, when the fin structure 104 is madeof Si. In other embodiments, about 0.01≤x≤0.05. Moreover, the S/Dstructure 120 in some embodiments include Si_(1-x-y)Ge_(x)As_(z), whereabout 0.01≤x≤about 0.1 (about 1 to about 10 mol %) and about0.01≤z≤about 0.1. Further, in other embodiments, the S/D structure 120includes Sn instead of Ge or together with Ge, for example, SiGeSnP,SiGeSnAs, SiSnP, SiGePAs, SiSnAs or SiGeSnPAs. In such a case, the totalamount of Sn and Ge is in a range from about 1 to about 10 mol %. Incertain embodiments, carbon (C) is further included in the S/D structure120.

In some embodiments, the S/D structure 120 includes two or moreepitaxial layers with different composition and/or different dopantconcentrations. In some embodiments, the Ge (and/or Sn) concentration inSiGeP of the S/D structures 120 increases as the distance from the finstructure 104 increases. The Ge (and/or Sn) concentration in a regioncloser to the fin structure 104 is smaller than that in a region closerto the outer surface of the S/D structure 120. The Ge (and/or Sn)concentration can gradually change or change in a stepwise manner.

For a p-type FET, SiGe or Ge may be used as the S/D structure 121 toform p-type FinFETs. In some embodiments, boron (B) is included in theS/D structure 121. In some embodiments, the S/D structure 121 includestwo or more epitaxial layers with different compositions and/ordifferent dopant concentrations.

As shown in FIGS. 4A and 4B, in some embodiments, the cross sections ofthe S/D structures 120 and/or 121 in the Y direction have substantiallya hexagonal shape, and in other embodiments, the cross sections of theS/D structures 120 and/or 121 has a diamond shape, a pillar shape or abar shape. The width W_(SD) of the S/D structure in the Y direction isin a range from about 25 nm to about 100 nm in some embodiments. Thethickness W_(EPI) of the S/D structure in the Y direction is in a rangefrom about 2 nm to about 10 nm in some embodiments.

After the S/D structures 120 and 121 are formed, as shown in FIGS.5A-5C, a first insulating layer 122 as a liner layer or a contact etchstop layer (CESL) is deposited to cover the S/D structures 120 and 121and on the sidewalls spacers of the dummy gate structure. The firstinsulating layer 122 acts as an etch stop during the patterning of asubsequently formed dielectric material. In some embodiments, the firstinsulating layer 122 includes SiO₂, SiCN, SiON, SiN and other suitabledielectric materials. In one embodiment, SiN is used. The firstinsulating layer 122 may be made of a plurality of layers that comprisescombinations of the above mentioned materials. The first insulatinglayer 122 may be deposited through one or more processes such as PVD,CVD, or ALD, although any acceptable process may be utilized. Othermaterials and/or processes may be used. In some embodiments, the firstinsulating layer 122 has a thickness between about 0.5 nm and about 10nm. Other thicknesses may be used in other embodiments.

After the first insulating layer 122 is formed, a first sacrificiallayer 115 is formed over the first insulating layer 122, as shown inFIGS. 6A-6C. In some embodiments, the first sacrificial layer 115includes one or more layers of silicon based dielectric material, suchas SiO₂, SiCN, SiON, SiOC, SiOH, SiN, or other suitable dielectricmaterials. In some embodiments, the first sacrificial layer 115 isformed through a film forming process, such as, CVD, PVD, ALD, FCVD, ora spin-on-glass process, although any acceptable process may beutilized. Subsequently, portions of the first insulating layer 122 areremoved using, for example, an etch process, CMP, or the like, to exposethe upper surface of the dummy gate electrode.

Subsequently, the first sacrificial layer 115 is partially recessed to alevel of the middle portion of the dummy gate electrode 90 in the Zdirection, thereby forming openings 116, as shown in FIGS. 7A-7C. Thefirst sacrificial layer 115 can be recessed by an etch-back processand/or wet etching. The remaining thickness of the recessed firstsacrificial layer 115 is in a range from about 40 nm to about 200 nm insome embodiments.

The openings 116 are filled with an insulating material, thereby forminga mask layer 95, as shown in FIGS. 8A-8C. In some embodiments, the masklayer 95 is made of one or more layers of SiOC, SiC, SiON, SiCN, SiOCN,SiN and/or SiO₂. In one embodiment, SiN is used. The mask layer 95 maybe deposited through one or more processes such as PVD, CVD, or ALD,although any acceptable process may be utilized. A planarizationoperation, such as, an etch-back process or CMP, may be performed toplanarize the upper surface of the mask layer 95 and hard mask layer 80,as shown in FIGS. 9A-9C. By the planarization operation, the hard masklayer 80 are removed, and the upper surface of the dummy gate electrodelayer 90 is exposed.

Subsequently, the dummy gate electrode 90 and the dummy gate dielectriclayer 91 are removed, as shown in FIGS. 10A-10C. The removal process mayinclude one or more etch processes. For example in some embodiments, theremoval process includes selectively etching using either dry or wetetching. When dry etching is used, the process gas may include CF₄,CHF₃, NF₃, SF₆, Br₂, HBr, Cl₂, or combinations thereof. Diluting gasessuch as N₂, O₂, or Ar may optionally be used. When wet etching is used,the etching solution (etchant) may include NH₄OH:H₂O₂:H₂O (APM), NH₂OH,KOH, HNO₃:NH₄F:H₂O, and/or the like. The dummy gate dielectric layer maybe removed using a wet etch process, such as a diluted HF acid. Otherprocesses and materials may be used.

After the dummy gate structure is removed, a metal gate structure isformed as shown in FIGS. 11A-11C. A gate dielectric layer 131 is formedover a channel region of the fin structure 102. In some embodiments, thegate dielectric layer 131 includes one or more high-k dielectric layers(e.g., having a dielectric constant greater than 3.9). For example, theone or more gate dielectric layers may include one or more layers of ametal oxide or a silicate of Hf, Al, Zr, combinations thereof, andmulti-layers thereof. Other suitable materials include La, Mg, Ba, Ti,Pb, Zr, in the form of metal oxides, metal alloy oxides, andcombinations thereof. Exemplary materials include MgO_(x),BaTi_(x)O_(y), BaSr_(x)Ti_(y)O_(z), PbTi_(x)O_(y), PbZr_(x)Ti_(y)O_(z),SiCN, SiON, SiN, Al₂O₃, La₂O₃, Ta₂O₃, Y₂O₃, HfO₂, ZrO₂, HfSiON,YGe_(x)O_(y), YSi_(x)O_(y) and LaAlO₃, and the like. The formationmethods of gate dielectric layer 131 include molecular-beam deposition(MBD), ALD, PVD, and the like. In some embodiments, the gate dielectriclayer 131 has a thickness of about 0.5 nm to about 5 nm. In someembodiments, the gate dielectric layer 131 is formed also on sides ofthe sidewall spacers 134.

In some embodiments, an interfacial layer (not shown) is formed over thechannel region 104 prior to forming the gate dielectric layer 131, andthe gate dielectric layer 131 is formed over the interfacial layer. Theinterfacial layer helps buffer the subsequently formed high-k dielectriclayer from the underlying semiconductor material. In some embodiments,the interfacial layer is a chemical silicon oxide, which may be formedby chemical reactions. For example, a chemical silicon oxide may beformed using deionized water+ozone (DIO₃), NH₄OH+H₂O₂+H₂O (APM), orother methods. Other embodiments utilize a different material orprocesses for the interfacial layer. In an embodiment, the interfaciallayer has a thickness of about 0.2 nm to about 1 nm.

After the gate dielectric layer 131 is formed, a gate electrode 130 isformed over the gate dielectric layer 131. The gate electrode 130 may bea metal selected from a group of W, Cu, Ti, Ag, Al, TiAl, TiAlN, TaC,TaCN, TaSiN, Mn, Co, Pd, Ni, Re, Jr, Ru, Pt, and Zr. In someembodiments, the gate electrode 130 includes a metal selected from agroup of TiN, WN, TaN, and Ru. Metal alloys such as Ti—Al, Ru—Ta, Ru—Zr,Pt—Ti, Co—Ni and Ni—Ta may be used and/or metal nitrides such as WN_(x),TiN_(x), MoN_(x), TaN_(x), and TaSi_(x)N_(y) may be used. In someembodiments, the gate electrode 130 has a thickness in the range ofabout 5 nm to about 100 nm. The gate electrode 130 may be formed using asuitable process such as ALD, CVD, PVD, plating, or combinationsthereof. A planarization process, such as a CMP, may be performed toremove excess materials.

In certain embodiments of the present disclosure, the gate electrode 130includes one or more work function adjustment layers (not shown)disposed on the gate dielectric layer 131. The work function adjustmentlayer is made of a conductive material such as a single layer of TiN,TaN, TaAlC, TiC, TaC, Co, Al, TiAl, HfTi, TiSi, TaSi or TiAlC, or amultilayer of two or more of these materials. For the n-channel FinFET,one or more of TaN, TaAlC, TiN, TiC, Co, TiAl, HfTi, TiSi and TaSi isused as the work function adjustment layer, and for the p-channelFinFET, one or more of TiAlC, Al, TiAl, TaN, TaAlC, TiN, TiC and Co isused as the work function adjustment layer.

Then, the gate electrode 130, the gate dielectric layer 131 and the workfunction adjustment layer are recessed, as shown in FIGS. 12A-12C, and agate cap layer 132 is formed on the recessed gate electrode 130, asshown in FIGS. 13A-13C. In some embodiments, when the gate electrode 130is mainly made of W, the gate electrode may be recessed using, forexample, dry etch process using Cl₂/O₂/BCl₃, at a temperature range of24° C. to 150° C., and at a pressure of below 1 Torr.

After recessing the gate electrode 130, the gate cap layer 132 is formedin the recess to protect the gate electrode 130 during subsequentprocesses, as shown in FIGS. 13A-13C. In some embodiments, the gate caplayer 132 includes SiO₂, SiCN, SiON, SiN, Al₂O₃, La₂O₃, SiN, acombination thereof, or the like, but other suitable dielectric filmsmay be used. The gate cap layer 132 may be formed using, for example,CVD, PVD, spin-on, or the like. Other suitable process steps may beused. A planarization process, such as a CMP, may be performed to removeexcess materials.

Then, as shown in FIGS. 14A-14C, the first sacrificial layer 115 is atleast partially removed from both side regions of the S/D structures 120and 121, to form openings 116. In some embodiments, the entire firstsacrificial layer 115 is removed. The first sacrificial layer 115 may beremoved by suitable etching operations, such as dry etching and/or wetetching. The etching operation substantially stops at the firstinsulating layer 122. In some embodiments, the first insulating layer122 has a thickness between about 0.5 nm and about 10 nm.

As shown in FIGS. 15A-15C, after the openings 116 are formed, a secondsacrificial layer 140 is formed in the openings 116. The secondsacrificial layer 140 is made of a material having a higher (e.g., 5 ormore) etching selectivity with respect to the materials of the firstinsulating layer 122 and/or the isolation insulating layer 105. In someembodiments, the second sacrificial layer 140 is made of one or morelayers of Group IV elemental or compound materials, such as Si, SiGe,SiC, Ge, SiGeC and GeSn, which may be crystalline, polycrystalline oramorphous and may be doped or un-doped. In other embodiments, the secondsacrificial layer 140 is made of one or more silicon based dielectriclayers of SiOC, SiC, SiON, SiCN, SiOCN, SiN and/or SiO₂. Aluminum baseddielectric materials, such as aluminum oxide, aluminum oxy-carbide andaluminum oxy-nitride may be used. A SOC (spin-on-carbon) may also beused. In certain embodiments, the second sacrificial layer 140 is madeof one or more layers of Group III-V compound semiconductors including,but not limited to, GaAs, GaN, InGaAs, InAs, InP, InSb, InAsSb, AlNand/or AlGaN. The second sacrificial layer 140 may be deposited throughone or more processes such as PVD, CVD, or ALD, although any acceptableprocess may be utilized. Other materials and/or processes may be used.In one embodiment, amorphous or poly Si is used as the secondsacrificial layer 140. In other embodiments, amorphous or polySi_(1-x)Ge_(x), where x is equal to or less than 0.4 is used as thesecond sacrificial layer 140.

A planarization operation, such as, an etch-back process or CMP, may beperformed to planarize the upper surface of the second sacrificial layer140. By the planarization operation, the upper surface of the gate caplayer 132 is exposed. After the planarization operation, the heightH_(sacr) of the second sacrificial layer measured from the surface ofthe first insulating layer 122 is in a range from about 100 nm to about350 nm in some embodiments.

Then, as shown in FIGS. 16A-16C, after the second sacrificial layer 140is formed, a mask pattern is formed over the second sacrificial layer140, and by using the mask pattern as an etching mask, the secondsacrificial layer 140 is patterned by using dry etching, thereby formingopenings 144 between the S/D structures 120 and 121. In someembodiments, the etching substantially stops at the first insulatinglayer 122. FIGS. 16A-16C show structure after the mask layer is removed.

The mask pattern may be formed by patterning a layer of suitable maskmaterial using a photo-etching operation. The etching operation mayinclude multiple etching processes using different plasma gases. In someembodiments, the mask pattern extends in the X direction over the secondsacrificial layer 140 and the gate cap layer 132. The mask pattern ismade of one or more layers of dielectric material, such as SiO₂, SiNand/or SiON, and/or TiN, or other suitable materials. The material forthe mask pattern may be deposited through one or more processes such asPVD, CVD, or ALD, although any acceptable process may be utilized. Othermaterials and/or processes may be used.

When a Si based material (e.g., poly-Si or amorphous Si) is used as thesecond sacrificial layer 140, the etching can be performed by plasma dryetching using, for example, a gas including HBr or a gas including Cl₂and SF₆. When SOC (spin-on-carbon) is used as the second sacrificiallayer 140, the etching can be performed by plasma dry etching using, forexample, a gas including N₂ and H₂ or a gas including SO₂ and O₂. When aSi oxide based material formed by FCVD is used as the second sacrificiallayer, the etching can be performed by plasma dry etching using, forexample, a gas including a fluorocarbon and/or fluorine.

When a Ge based material (e.g., Ge or SiGe) is used as the secondsacrificial layer 140, the etching can be performed by plasma dryetching using, for example, a gas including a fluorocarbon or a gasincluding a halogen. During the etching, the substrate may be heated ata temperature between about 20° C. to about 200° C.

In some embodiments, the opening width W_(SP) in the Y direction is in arange from about 5 nm to about 100 nm. In certain embodiments, theopening width W_(SP) is in a range from about 10 nm to about 40 nm. Thewidth W_(sp) may be other values depending on design rules and/or typesof semiconductor devices.

It is noted that as shown in FIGS. 16A and 16C, the first insulatinglayer 122 and/or the gate cap layer 132 are not substantially etchedduring the patterning of the second sacrificial layer 140 in someembodiments. In other words, the materials for the first insulatinglayer 122 and/or the gate cap layer 132 have a high etching selectivity(e.g., 5 or more) with respect to the second sacrificial layer 140(i.e., lower etching rate than the second sacrificial layer).

Subsequently, as shown in FIGS. 17A-17C, a second insulating layer 146,as a liner layer, is conformally formed over the patterned secondsacrificial layer 140 and the isolation insulating layer 105. The secondinsulating layer 146 is also formed on the sidewall spacers 134 and thegate cap layer 132.

In some embodiments, the second insulating layer 146 includes SiO₂,SiCN, SiON, SiCN, SiOCN and SiN, but other suitable dielectric materialsmay be used. In one embodiment, silicon nitride based dielectricmaterial, such as SiN, is used. The second insulating layer 146 may bemade of a plurality of layers that comprises combinations of the abovementioned materials. In one embodiment, two layers of silicon baseddielectric material, at least one of which is silicon nitride basedmaterial, are used as the second insulating layer 146. In otherembodiments, an aluminum based dielectric layer is used as one layer ofthe second insulating layer 146. In certain embodiments, the secondinsulating layer 146 includes a silicon nitride based dielectric layerand a dielectric layer made of a material other than a silicon nitridebased material.

The second insulating layer 146 has a higher selective etching ratio tosilicon compared to the etching rate of SiO₂ to silicon. For example,the etching rates of silicon nitride, silicon oxide, and silicon inH₃PO₄ are respectively about 50:5:1.

The second insulating layer 146 may be deposited through one or moreprocesses such as PVD, CVD, molecular layer deposition (MLD) or ALD,although any acceptable process may be utilized. Other materials and/orprocesses may be used. In the case of ALD, for example, SiH₄ (silane),SiH₂Cl₂ (dichlorosilane), and/or SiCl₄ (silicon tetrachloride), and/orother suitable silicon-containing precursor for the nitride-containingliner layer may be used as precursor for ALD process.

In some embodiments, the deposition temperature of the second insulatinglayer 146 is maintained below about 500° C. In other embodiments, thetemperature is below about 400° C. The temperature is maintained low tominimize thermal impact on the threshold voltage of themetal-gate/high-k dielectric stack that has already been formed.

In some embodiments, the second insulating layer 146 has a thicknessbetween about 1 nm and about 15 nm. In other embodiments, the thicknessis about 3 nm to about 10 nm. Other thicknesses are used in otherembodiments.

After the second insulating layer 146 is formed, a first interlayerdielectric (ILD) layer 145 is formed to fill the openings 144 and overthe second sacrificial layer 140.

The ILD layer 145 may include a single layer or multiple layers. In someembodiments, the ILD layer 145 includes SiO₂, SiCN, SiOC, SiON, SiOCN,SiN or a low-k material, but other suitable dielectric film may be used.The ILD layer 145 may be formed by CVD, PECVD or ALD, FCVD, or aspin-on-glass process. A planarization process, such as a CMP process,may be performed to remove excess materials. By the planarizationprocess, the upper surface of the second sacrificial layer 140 (and thecap insulation layer 132) is exposed in some embodiments.

When a FCVD is used, a curing process is performed on the flowableisolation dielectric precursor in some embodiments. The curing processmay include UV curing, ozone (O₃) plasma curing or low-temperature O₃plasma+UV curing (LTB+UV curing), so as to transfer the flowableisolation dielectric precursor into the dielectric layer such as siliconoxide layer. A processing temperature range of the UV curing process isbetween about 0° C. and about 10° C., in some embodiments. A processingtemperature range of the O₃ plasma curing process is between about 100°C. and about 250° C. in some embodiments. A processing temperature rangeof the LTB+UV curing process is between about 30° C. and about 50° C.,in some embodiments. The curing process may be performed only one timeafter the deposition process to reduce the process time, but not limitedthereto, in some embodiments. The deposition process and the curingprocess can be alternately performed. In other embodiments, the flowableisolation dielectric precursor can also be directly transferred into thedielectric layer through an oxidation process by directly introducingnitrogen, oxygen, ozone or steam.

In order to further increase the structural density of the ILD layer,after the curing process, a thermal treatment process may be performedon the isolation dielectric layer. The thermal treatment processincludes a steam containing thermal treatment process (wet annealing)and a nitrogen-containing thermal treatment process (dry annealing). Aprocessing temperature range of the steam-containing thermal treatmentis between about 400° C. and about 1000° C., in some embodiments, andthe processing temperature of the nitrogen-containing thermal treatmentprocess is between about 1000° C. and about 1200° C. In otherembodiments, the temperature of thermal treatment can be reduced toabout 400° C. by exposing the film to ultra-violet radiation, e.g., in aultra-violet thermal processing (UVTP) process.

After the curing or treatment, the ILD layer may have a relativepermittivity of less than 6, in some embodiments.

In other embodiments, a spin on dielectric (SOD) process is performed toform the ILD layer 145. In this embodiment, the second insulating layer146, a nitride-containing liner layer, is formed in the prior process toprovide a suitable inter layer to the deposited isolation dielectriclayer in contact isolation region by SOD process. Therefore, the ILDlayer may be formed by the SOD process using suitable precursor.

In the SOD process for the ILD layer 145, the precursor may beorganosilicon compounds, such as but not limited to siloxane,methylsiloxane, polysilazane and hydrogensilsesquioxane,perhydropolysilazane (PHPS), and other suitable materials. The SODprecursor is dissolved in a compatible organic solvent commonly used incoating solutions of spin-on chemicals. Suitable organic solventsinclude, for example, dibutyl ether (DBE), toluene, xylene,propyleneglycolmonomethyletheracetate (PGMEA), ethyl lactate andisopropyl alcohol (IPA), and the like, preferably use xylene as thesolvent for PHPS. The concentration of the SOD precursor in solution canbe varied to adjust the consistency (i.e., viscosity) of the solutionand thickness of the coating. A solution containing between about 4% toabout 30% by weight of SOD precursor can be used, in some embodiments.In other embodiments, a solution containing about 8% to about 20% byweight SOD precursor is used. Additional minor amounts of additives suchas surfactants and binders can be included in the solution.

The wafer is spun to uniformly spread SOD precursor from wafer center toedge during precursor spin-on process. The spin speed of cast rotationfor SOD precursor coating on substrate is from 100 rpm to 3000 rpm, insome embodiments, for a 12 inch wafer. The dynamic dispense rate of SODprecursor is around 1 ml/sec in some embodiments, and the dispensepuddle will spread completely to the edge of the wafer before mainspeed. The SOD precursor can therefore totally cover the bottom ofcontact isolation hole and fill the opening 144.

Subsequently, a prebaking process is performed after SOD deposition tostabilize the SOD layer. The prebaking process is performed at lowtemperature in a range of about 100° C. to about 200° C. in air ambient,in some embodiments. A thermal treatment process is performed afterprebaking process to densify the SOD layer. The thermal treatmentprocess is an annealing process performed at high temperature in a rangeof about 400° C. to about 1100° C., in some embodiments. The annealingprocess may be a wet annealing process using a gas including steam, O₂and H₂ gas or a dry annealing process using a gas including N₂ and O₂gas. In the other embodiments, the thermal treatment process uses plasmaat a lower temperature in a range of about 150° C. to about 400° C. Thepartial pressure ratio of water vapor (H₂O) to hydrogen (H₂) preferablyis controlled to a value in a range of about 1×10⁻¹¹ to about 1.55.

Subsequently, as shown in FIGS. 18A-18D, the second sacrificial layer140 is removed, thereby forming contact openings 148 and 149 to exposethe S/D structures 120, 121 covered by the first insulating layer 122.The etching operation to remove the second sacrificial layer 140 may beisotropic or anisotropic. In addition, the first insulating layer 122 isremoved, thereby exposing the S/D structures 120, 121.

When a Si based material (e.g., poly-Si or amorphous Si) is used as thesecond sacrificial layer 140, the etching can be performed by plasma dryetching using a gas including Cl₂ and NF₃ or a gas including F₂, or wetetching using NH₄OH and/or tetramethylammonium (TMAH). When SOC(spin-on-carbon) is used as the second sacrificial layer 140, theetching can be performed by plasma dry etching using, for example, a gasincluding N₂ and H₂ or a gas including SO₂ and O₂. When a Si oxide basedmaterial formed by FCVD is used as the second sacrificial layer, theetching can be performed by wet etching using, for example, HF orbuffered HF (BHF).

When a Ge based material (e.g., Ge or SiGe) is used as the secondsacrificial layer 140, the etching can be performed by plasma dryetching using, for example, ozone, or wet etching using a solutioncontaining NH₄OH and H₂O₂ or a solution containing HCl and H₂O₂.

The remaining first insulating layer 122 can be removed by using asuitable etching operation. In some embodiments, during the etching ofthe first insulating layer 122, the second insulating layer 146 is alsoetched when the second insulating layer 146 is made of the same orsimilar material as the second insulating layer 122. In certainembodiments, the second insulating layer 146 is fully removed from thewall of the contact openings 148 and 149. However, even in such a case,the second insulating layer 146 remains at the bottom of the ILD layer145 in some embodiments.

Since the etching rate for the second sacrificial layer 140 is higherthan other materials, it is possible to remove the second sacrificiallayer 140 without causing damage in the other layers, for example, thegate cap layer 132, the sidewall spacers 134, the first insulating layer122, the ILD layer 145 and/or the second insulating layer 146.

The width W_(CH) along the Y direction of the openings 148, 149 is in arange from about 10 nm to about 100 nm in some embodiments. In otherembodiments, the width W_(CH) is in a range from about 15 nm to about 50nm.

After the second sacrificial layer and the first insulating layer 122formed on the S/D structures 120, 121 are removed, a conductive materialis filled in the contact openings 148, 149, thereby forming S/D contacts150, as shown in FIGS. 19A-19C.

In some embodiments, a silicide layer 127 is formed on the exposed S/Dstructures 120, 121. The metal silicide formation process may form ametal silicide on the side portions of the S/D structures. The metalsilicide formation process includes a metal film deposition on the S/Dstructures, a thermal treatment to form a metal silicide at theinterface or surface of the S/D structures, and an etching process toremove the excess unreacted metal. The metal silicide comprisesTiSi_(x), NiSi_(x), CoSi_(x), NiCoSi_(x), and TaSi_(x), but othersuitable silicide materials may be used. In some embodiments, thesilicide layer has a thickness between about 0.5 nm and about 10 nm. Inother embodiments, a silicide layer is not formed at this stage of themanufacturing operations, and may be formed at an earlier manufacturingstage, e.g., before forming the first insulating layer 122. In someembodiments, a metal film is also formed on the second insulating layer146 and the isolation insulating layer 105. The metal films not formedon the S/D epitaxial layer and the metal films not consumed to form thesilicide layer are removed by a suitable etching operation in someembodiments. In other embodiments, the metal films are not removed andremain.

The S/D contacts 150 may include a single layer or a multi-layerstructure. For example, in some embodiments, the contact 150 includes acontact liner layer, such as a diffusion barrier layer, an adhesionlayer, or the like, and a contact body formed over the contact linerlayer in the contact openings 148, 149. The contact liner layer mayinclude Ti, TiN, Ta, TaN, or the like formed by ALD, CVD, or the like.The contact body may be formed by depositing a conductive material, suchas one or more layers of Ni, Ta, TaN, W, Co, Ti, TiN, Al, Cu, Au, alloysthereof, combinations thereof, or the like, but other suitable metalsmay also be used. A planarization process, such as a CMP, may beperformed to remove excess material from a surface of the ILD layer 145.

After the S/D contact 150 is formed, the height H_(g) of the gatestructure including the gate cap layer 132 measured from the top of thefin structure 102 is in a range from about 20 nm to 100 nm and theheight of the metal gate 130 measured from the top of the fin structure102 is in a range from about 10 nm to about 60 nm in some embodiments.

After forming the contact 150, further CMOS processes are performed toform various features such as additional interlayer dielectric layers,contacts/vias, interconnect metal layers, and passivation layers, etc.

As set forth above, after the S/D structure 120 is formed, variousoperations including film formation operations are performed. Some ofthe subsequent operations require heating operations, and some of theheating operations require higher temperature such as 700° C. or more(and 1200° C. or less). If Ge and/or Sn is not included in the S/Dstructure 120 (e.g., SiP or SiAs) for an n-type FET, deactivation of P(or As) would occur. However, in the foregoing embodiments, since Geand/or Sn is included in the S/D structure 120 (e.g., SiP) for then-type FET, deactivation of P (or As) can be suppressed, and thus ahigher number of activated phosphorous (or arsenic) can be obtained.

FIGS. 20A-22C illustrate various processes in a semiconductor devicefabrication process in accordance with other embodiments of the presentdisclosure. Throughout the various views and illustrative embodiments,like reference numbers are used to designate like elements. In FIGS.20A-22C, the “A” figures (e.g., FIGS. 20A, 21A, etc.) illustrate aperspective view, the “B” figures (e.g., FIGS. 20B, 21B, etc.)illustrate a cross-sectional view along the Y direction corresponding toline Y1-Y1 illustrated in FIG. 3A, and the “C” figures (e.g., FIG. 20C,21C, etc.) illustrate a cross-sectional view along the X directioncorresponding to line X1-X1 illustrated in FIG. 3A. It is understoodthat additional operations can be provided before, during, and afterprocesses shown by FIGS. 20A-22C, and some of the operations describedbelow can be replaced or eliminated, for additional embodiments of themethod. The order of the operations/processes may be interchangeable.Material, configuration, dimensions and/or processes the same as orsimilar to the foregoing embodiments described with respect to FIGS.1A-19C may be employed in the following embodiments, and detailedexplanation thereof may be omitted.

After the structure shown in FIGS. 13A-13C is formed, the firstsacrificial layer 115, which is used as a first interlayer dielectriclayer in this embodiment, is patterned to form contact openings 148′ and149′, as shown in FIGS. 20A-20C. One or more lithography and etchingoperations are employed to form the contact openings 148′ and 149′.

Similar to the operation explained with FIGS. 19A-19C, a silicide layer127 is formed on the exposed S/D structures 120, 121. The conductivematerial layer 150 is formed in the openings 148′ and 149′ and the ILDlayer 115, as shown in FIGS. 21A-21C. The conductive material layer forthe S/D contacts 150 may include a single layer or a multi-layerstructure. A planarization process, such as a CMP, may be performed toremove excess material from a surface of the ILD layer 145, as shown inFIGS. 22A-22C.

After forming the contact 150, further CMOS processes are performed toform various features such as additional interlayer dielectric layers,contacts/vias, interconnect metal layers, and passivation layers, etc.

It will be understood that not all advantages have been necessarilydiscussed herein, no particular advantage is required for allembodiments or examples, and other embodiments or examples may offerdifferent advantages.

For example, in the present disclosure, by containing Ge and/or Sn in anepitaxial source/drain structure for an n-type FET, it is possible tosuppress de-activation of the P and/or As in the epitaxial source/drainstructure, thereby improving contact resistance between the epitaxialsource/drain structure and the source/drain metal contact.

In accordance with an aspect of the present disclosure, a semiconductordevice includes a field effect transistor (FET). The FET includes achannel region and a source/drain region disposed adjacent to thechannel region, and a gate electrode disposed over the channel region.The FET is an n-type FET, and the channel region is made of Si. Thesource/drain region includes an epitaxial layer includingSi_(1-x-y)M1_(x)M2_(y), where M1 is one or more of Ge and Sn, and M2 isone or more of P and As, and 0.01≤x≤0.1. In one or more of the foregoingor following embodiments, M1 is Ge. In one or more of the foregoing orfollowing embodiments, M2 is P. In one or more of the foregoing orfollowing embodiments, 0.01≤x≤0.05. In one or more of the foregoing orfollowing embodiments, 0.01≤y≤0.1. In one or more of the foregoing orfollowing embodiments, M1 is Ge and a concentration of Ge decreases froman outer surface of the epitaxial layer toward inside the epitaxiallayer.

In accordance with another aspect of the present disclosure, asemiconductor device includes fin field effect transistors (FinFETs).The semiconductor device includes an n-type FinFET and a p-type FinFET.The n-type FinFET includes a first fin structure, a first source/drainstructure and a first source/drain contact in contact with the firstsource/drain structure. The p-type FinFET includes a second finstructure, a second source/drain structure and a second source/draincontact in contact with the second source/drain structure. The firstsource/drain structure includes a first epitaxial layer includingSi_(1-x-y)M1_(x)M2_(y), where M1 is one or more of Ge and Sn, and M2 isone or more of P and As, and 0.01≤x≤0.1. In one or more of the foregoingor following embodiments, M1 is Ge. In one or more of the foregoing orfollowing embodiments, M2 is P. In one or more of the foregoing orfollowing embodiments, 0.01≤x≤0.05. In one or more of the foregoing orfollowing embodiments, 0.01≤y≤0.1. In one or more of the foregoing orfollowing embodiments, the second source/drain structure includes asecond epitaxial layer including SiGe or Ge. In one or more of theforegoing or following embodiments, the second epitaxial layer furtherincludes boron. In one or more of the foregoing or followingembodiments, M1 is Ge and a concentration of Ge increases from a regionadjacent to the first fin structure to a region adjacent to an outersurface of the first epitaxial layer. In one or more of the foregoing orfollowing embodiments, the concentration of Ge continuously increases.In one or more of the foregoing or following embodiments, theconcentration of Ge increases in a stepwise manner. In one or more ofthe foregoing or following embodiments, the semiconductor device furtherincludes a dielectric layer separating the first source/drain structureand the second source/drain structure. The dielectric layer is made ofsilicon-based insulating material, and contains Ge at or near aninterface between the dielectric layer and one of the first and secondsource/drain contacts. In one or more of the foregoing or followingembodiments, the second source/drain structure includes a secondepitaxial layer, the first epitaxial layer wraps around a source/drainregion of the first fin structure, and the second epitaxial layer wrapsaround a source/drain region of the second fin structure. In one or moreof the foregoing or following embodiments, the first source/draincontact wraps around the first epitaxial layer, and the secondsource/drain contact wraps around the second epitaxial layer.

In accordance with another aspect of the present disclosure, in a methodof forming a semiconductor device including a fin field effecttransistor (FinFET), a first sacrificial layer is formed over asource/drain structure of a FinFET structure and an isolation insulatinglayer. The first sacrificial layer is patterned, thereby forming anopening. The first liner layer is formed on the isolation insulatinglayer in a bottom of the opening and on at least side faces of thepatterned first sacrificial layer. After the first liner layer isformed, a dielectric layer is formed in the opening. After thedielectric layer is formed, the patterned first sacrificial layer isremoved, thereby forming a contact opening over the source/drainstructure. A conductive layer is formed in the contact opening. TheFinFET is an n-type FET, and the source/drain structure includes anepitaxial layer including Si_(1-x-y)M1_(x)M2_(y), where M1 is one ormore of Ge and Sn, and M2 is one or more of P and As, and 0.01≤x≤0.1.

The foregoing outlines features of several embodiments or examples sothat those skilled in the art may better understand the aspects of thepresent disclosure. Those skilled in the art should appreciate that theymay readily use the present disclosure as a basis for designing ormodifying other processes and structures for carrying out the samepurposes and/or achieving the same advantages of the embodiments orexamples introduced herein. Those skilled in the art should also realizethat such equivalent constructions do not depart from the spirit andscope of the present disclosure, and that they may make various changes,substitutions, and alterations herein without departing from the spiritand scope of the present disclosure.

What is claimed is:
 1. A method of forming a semiconductor device,comprising: forming a first source/drain structure over a first finstructure; forming a second source/drain structure over a second finstructure; and forming a gate structure over the first and secondsource/drain structures, wherein the first source/drain structure isdisposed adjacent to the second source/drain structure, and wherein thefirst source/drain structure includes a first epitaxial layer made ofSi_(1-y-a-b)Ge_(a)Sn_(b)M2_(y), where M2 is P or As, 0<a, 0<b,0.01≤(a+b)≤0.1, and 0.01≤y≤0.1.
 2. The method of claim 1, wherein thesecond source/drain structure includes a second epitaxial layerincluding SiGe or Ge.
 3. The method of claim 2, wherein the secondepitaxial layer further includes boron.
 4. The method of claim 2,wherein the first epitaxial layer wraps around a source/drain region ofthe first fin structure, and the second epitaxial layer wraps around asource/drain region of the second fin structure.
 5. The method of claim1, wherein a concentration of Ge and Sn increases from a region adjacentto the first fin structure to a region adjacent to an outer surface ofthe first epitaxial layer.
 6. The method of claim 5, wherein theconcentration of Ge and Sn continuously increases.
 7. The method ofclaim 5, wherein the concentration of Ge and Sn increases in a stepwisemanner.
 8. The method of claim 5, wherein the concentration of Gecontinuously increases.
 9. A method of forming a semiconductor device,the method comprising: forming a fin structure; forming a source/drainstructure in the fin structure; and forming a gate electrode over thefin structure, wherein the source/drain structure includes a firstepitaxial layer made of Si_(1-y-a-b)Ge_(a)Sn_(b)M2_(y), where M2 is P orAs, 0<a, 0<b, 0.01≤(a+b)≤0.1, and 0.01≤y≤0.1.
 10. The method of claim 9,wherein a concentration of Ge and Sn increases in a stepwise manner froma region adjacent to the fin structure to a region adjacent to an outersurface of the first epitaxial layer.
 11. The method of claim 10,wherein the concentration of Ge continuously increases.
 12. The methodof claim 9, wherein a concentration of Ge and Sn continuously increasesfrom a region adjacent to the fin structure to a region adjacent to anouter surface of the first epitaxial layer.
 13. The method of claim 9,wherein a concentration of Ge and Sn is in a range from about 0.5×10²¹cm⁻³ to about 4.0×10²¹ cm⁻³.
 14. The method of claim 9, wherein thefirst epitaxial layer wraps around a source/drain region of the finstructure.
 15. A method of forming a semiconductor device, the methodcomprising: forming a source/drain structure in a fin structure, whereinthe source/drain structure includes a first epitaxial layer made ofSi_(1-y-a-b) Ge_(a)Sn_(b)M2_(y), where M2 is P or As, 0<a, 0<b,0.01≤(a+b)≤0.1, and 0.01≤y≤0.1; forming a sacrificial layer covering thesource/drain structure; patterning the first sacrificial layer to form acontact opening; and forming a source/drain contact in the contactopening.
 16. The method of claim 15, wherein a concentration of Ge andSn increases from a region adjacent to the first fin structure to aregion adjacent to an outer surface of the first epitaxial layer. 17.The method of claim 16, wherein the concentration of Ge and Sn increasesin a stepwise manner.
 18. The method of claim 16, wherein theconcentration of Ge and Sn continuously increases.
 19. The method ofclaim 16, wherein the concentration of Ge continuously increases. 20.The method of claim 15, wherein a concentration of Ge and Sn is in arange from about 0.5×10²¹ cm⁻³ to about 4.0×10²¹ cm⁻³.